On-Site Structural Steel Welding — Safe Work Method Statement

Field welding of structural steel is different from welding in a fabrication shop. The welder is often working from an EWP, scaffold or beam-level platform, the steel may be part of a partly erected frame, sparks and slag fall onto people and materials below, and wind and rain affect both safety and weld quality. Work at height with a fall of more than 2 metres and work in an area with powered mobile plant such as cranes, EWPs and telehandlers both apply on most jobs, so it is High Risk Construction Work and needs a SWMS. This template covers the welding itself; the lifting and erection of the steel needs its own SWMS for structural steel erection.

The job-specific hazards are these. Falling sparks and slag from height travel much further than at ground level and can land on workers, scaffold sheeting, timber formwork, insulation or materials stored below, so you need catch blankets or trays and a fire watch underneath, not just at the welder. The welding current must return through the earth lead clamped close to the weld, never through crane hooks, slings, chains, bearings or bolted connections, which it can damage or overheat. Outdoors and in wet conditions the electric shock risk rises, so use a welding set with a voltage reduction device for manual metal arc work where the Welding Processes code recommends it, keep leads off wet ground, and stop in rain. Wind strips shielding gas from gas-shielded processes, so screen the work or use a process suited to site conditions. Preheating with gas torches adds LPG or oxy-fuel hazards. When welding on existing structures, old paint may contain lead and must be removed and assessed before heating.

Structural welds must be made to the project's welding procedures, normally under AS/NZS 1554, by welders qualified for the process and position, and inspected by the method and extent the engineer specifies before the structure is relied on. Do not cut, weld or remove temporary bolts and bracing on members that are carrying load unless the engineer or erection sequence allows it.

The SWMS must cover access and fall protection at each weld location, fire controls above and below, electrical safety of the welding set and leads, weather limits, coordination with the erection crew and crane, and weld inspection hold points.

Customise this template with: the site and principal contractor; the structure and connections to be welded; the welding procedure references and welder qualifications; the access equipment and operator licences; the hot work permit and fire watch arrangements below each work area; weather limits; preheat method and gas cylinders; the inspection and testing requirements; and coating information for any existing steel.